Abstract
This paper describes a hip implant model designed to assess the Fused Deposition Modeling (FDM) process for manufacturing investment casting master patterns. In addition, an indirect approach toward manufacturing master pattern via silicone rubber moulding in conjunction with 3D Printing process manufactured hip implant master pattern has been investigated. The dimensional accuracies of the manufactured AM master patterns and the wax pattern are presented. Finally, cost and lead time comparisons carried out between FDM ABS pattern manufacturing, indirect pattern manufacturing via silicone rubber moulding and conventional pattern manufacturing by metal mould are also presented.
Highlights
The development of CAD/CAM technologies, and later Additive Manufacturing (AM) technology, enabled the production of orthopaedic implants of highly complex structures and shapes
This paper describes a hip implant model designed to assess the Fused Deposition Modeling (FDM) process for manufacturing investment casting master patterns
The accuracy of fabricated AM and wax patterns of hip implants was determined by measuring the critical dimensions and comparing them with the corresponding nominal measures
Summary
Control measurements were conducted and the accuracy of the AM and wax pattern of the hip implant was determined. The time and the costs of developing a master pattern by direct and indirect approach were analysed. Direct approach to manufacturing of ABS master pattern of hip implant by FDM technology The thermoplastic ABS material was used on the Stratasys Prodigy Plus FDM system (Rapid Prototyping Laboratory, Czech Technical University in Prague, Czech Republic) to fabricate the pattern with FDM technology. The pattern of the hip implant was made with a hollow internal structure, thust fulfilling one of the requirements for making master patterns by investment casting, namely, the small volume mass. The hip model was made as a quasihollow pattern, i.e. with internal mesh structure and wall thickness between 1.5 mm and 1.9 mm.
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